Mounting and Operating Instructions EB 8039 EN
Contents
1. DN 100 version 7 Valve bonnet 7 1 Diaphragm plate 7 2 Nut Lock nut 7 3 Nut 7 4 Milled part Valve body Flat gasket Nuts Seat Plug assembly Plug stem Lock nut Washer Packing Spring PTFE V ring packing Washer Valve bonnet Guide bushing Threaded bushing Diaphragm Spring Spring plate Top diaphragm case Loading pressure connection Nuts bolts and washers Handwheel optional 8039EN 5 Maintenance Replacing parts 3 Maintenance Replacing parts The control valve is subject to natural wear in particular at the seat plug and packing Depending on the operating conditions the valve must be checked at regular intervals to prevent problems occurring If leakage occurs this could be caused by a defective packing If the valve does not seal properly the tight shut off may be impeded by dirt or other im purities caught between the seat and plug or by damaged seating surfaces Remove the parts clean them thoroughly and replace them with new ones if neces sary Before performing any work on the valve you must disassemble the control valve You only need to remove the top diaphragm case when the actuator is defective due to a damaged diaphragm Caution Before servicing or disassembling the control valve depressurize the concerned section of the plant and drain it Wait until the medium has cooled down if necessary As valves are not free of dead cavities rememb2. Pneumatic On off Valve Type 3351 Fig 1 Type 3351 Mounting and Operating Instructions EB 8039 EN Edition January 2005 Contents Contents Page 1 Design and principle of operation 4 2 Installation s y uer eX OOo e ek ee 4 2 1 Direction of flow 4 3 Maintenance Replacing 3 1 Disassembly for valves in 15 80 7 3 2 Reassembling valve in DN 15 080 8 3 3 Disassembly for valves in 100 9 3 4 Reassembling valve in 100 9 3 5 Friction fest Se usu itp us baked Ga E ROSE Ido 10 4 Description 11 5 Customer inquiries les 11 Note Non electrical actuators and valves do not have their own potential ignition source according to the risk assessment in the rare incident of an operating fault corresponding to EN 13463 1 2001 paragraph 5 2 and therefore do not fall within the scope of the European Directive 94 9 EC Refer to paragraph 6 3 of EN 60079 14 1977 VDE 0165 Part 1 concerning connection to equipotential bonding system 2 8039 EN Safety instructions General safety instructions The control valve may only be mounted started up or serviced by fully trained and qualified personnel observing the accepted industry codes and practices Mak
3. e sure employees or third persons are not exposed to any danger All safety instructions and warnings in these mounting and operating instructions particularly those concerning assembly start up and maintenance must be observed The control valves fulfill the requirements of the European Pressure Equipment Directive 97 23 EC Valves with a CE marking have a declaration of conformity that includes information about the applied conformity assessment procedure The corresponding declaration of conformity can be viewed and downloaded on the Internet at http www samson de For appropriate operation make sure that the control valve is only used in areas where the operating pressure and temperatures do not exceed the operating values which are based on the valve sizing data submitted in the order The manufacturer does not assume any responsibility for damage caused by external forces or any other external influence Any hazards which could be caused in the control valve by the process medium operating pressure signal pressure or by moving parts are to be prevented by means of the appropriate measures Proper shipping and appropriate storage of the control valve are assumed Caution For installation and maintenance work on the valve make sure the relevant section of the pipeline is depressurized and depending on the process medium drained as well If necessary allow the control valve to cool down or warm up to reach ambient temperature pri
4. ed to be replaced with new ones as well EB8039 EN 7 Maintenance Replacing parts Thoroughly clean all parts as well os the packing chamber 3 2 Reassembling valve in DN 15 to 80 1 For version with Fail Close action first place the plug in the body for version with Fail Open action push plug into the valve bonnet Carefully degrease the plug stem thread 2 Apply sealant order no 8150 0119 to the seat and screw it in using the seat wrench observe tightening torque ac cording to Table 1 3 Packing first insert spring 4 1 and washer 4 3 in the packing chamber then the V ring packing parts 4 2 after applying lubricant order no 8150 0111 to them Loosely screw in threaded bushing 5 2 4 Insert flat gasket 1 1 into the body Place the valve bonnet 5 on the body for version with Fail Close action lift the plug stem and carefully guide through the packing Fasten down valve bonnet by tightening the nuts 1 2 evenly Screw lock nut 3 2 onto the plug stem until the end of the thread place washer 3 3 on top 5 Insert spring 5 5 into the valve bonnet and align according to Fig 3 Screw spring plate 5 6 on the plug stem by hand until it rests on the spring Align the spring plate cams so that the 8 EB8039EN plate is positioned above the recess of the diaphragm case Screw on mounting device Evenly tighten fastening bolts until the spring is preloaded approx 6 mm by t
5. er that there might still be residual media in the valve This particularly applies for valve version with bellows seal or insulating section It is recommended to remove the valve from the pipeline for maintenance Mounting device Spacer used for disassembly Fig 3 Mounting device DN 15 to 80 Alignment of spring EB 8039 EN Note Before servicing or disossembling the control valve disconnect and shut off the supply air The procedures to disassemble the valve with Fail Close action and the valve with Fail Open action are not the same due to the plug arrangement mounting device see Fig 3 and Table 1 is needed as the spring 5 5 in the actuator is preloaded To take out the seat ring a special seat tool Table 1 is necessary Refer to Table 2 for the required tightening torques 3 1 Disassembly for valves in DN 15 to 80 1 Remove nuts and bolts on the actuator For versions with handwheel turn the wheel in order to remove any tension acting on the spring plate 5 6 Lift off diaphragm case 5 7 and re move diaphragm 2 Place spacer approx 5 mm on the spring plate as shown in Fig 3 Place mounting device on top and fasten using three fastening nuts and bolts Tighten nuts so that the spring plate 5 6 is preloaded evenly As a result the plug 3 starts to move away from the seot 3 Loosen threaded bushing 5 2 com pletely Spray the
6. he spring plate Apply adhesive order no 8121 9014 to the plug stem thread Place the socket wrench or hex screwdriver to turn the plug stem counterclockwise as far as it will go For version with Fail Close action con tinue to preload the mounting device step by step until it s three stop bushings touch the diaphragm case For version with Fail Open action continue to preload the mounting device step by step until it has a distance of approx 2 mm from the diaphragm case Turn plug in this position counterclock wise as far as it will go then tighten lock nut 3 2 Remove mounting device Insert diaphragm 5 4 place dia phragm case on top and tighten evenly Tighten threaded bushing 5 2 as far as it will go 3 3 Disassembly for valves in DN 100 Remove nuts and bolts on the actuator For versions with handwheel turn the wheel in order to remove any tension acting on the diaphragm plate 7 1 Lift off diaphragm case 5 7 Loosen nut 7 3 and unscrew it while holding the plug stem stationary at the milled part with an open wrench SW 14 Remove diaphragm plate and springs Unscrew nut 7 2 together with lock nut Carefully pull valve bonnet 7 upwards for version with Fail Close action over the plug stem and for version with Fail Open action together with the plug stem If you want to replace the seat and or the plug for the version with Fail Close action the seat needs to be
7. ing the nuts 1 2 evenly Screw lock nut 3 2 onto the plug stem until the end of the thread place washer 3 3 on top 5 Screw nut and lock nut onto the plug stem according to the dimension R Fig 2 and tighten On doing so make sure the plug is resting on the seat EB 8039EN 9 Maintenance Replacing parts Insert springs into the valve bonnet and align the end of the springs towards the middle 7 Place diaphragm plate on the end of the plug stem 3 1 while pulling the plug stem as far as possible out of the valve Screw nut 7 3 on tight while holding the plug stem stationary at the milled part with an open wrench SW 14 8 Align the holes in the diaphragm place diaphragm case on top and fasten tight by tightening the bolt 5 9 evenly 3 5 Function test After reassembling the valve we recom mend performing a function test to check whether the valve functions properly To proceed connect a suitable source of compressed air to the loading pressure con nection on the diaphragm case Valve with Fail Close action The valve must be closed when O bar air pressure is applied it must start to open when at least 3 bar is applied and be com pletely open at 6 bar Valve with Fail Open action The valve must still be open when 0 5 bar air pressure is applied and completely closed at 4 5 bar Table 1 Order no Nominal size pr reae DN 80 DN 100 Moun
8. ium Flow rate in m3 h Minimum and maximum signal pressure Has a strainer been installed Installation drawing Dimensions and weights Refer to the Data Sheet T 8039 EN for the dimensions and weights of the various valve versions 8039 EN 11 SAMSON AG MESS UND REGELTECHNIK Weism llerstra e 3 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fax 49 69 4009 1507 Internet http www samson de EB 8039 EN S Z 2005 02
9. lock nut 3 2 stuck to the plug stem with adhesive as well as the ends of the plug stem with solvent Use a hot air gun to soften the adhesive Maintenance Replacing parts and loosen the lock nut 3 2 Position socket wrench or hex screw driver DN 65 80 and carefully turn the plug stem clockwise until its height has changed by approx mm Loosen fastening bolts of the mounting device as well as the plug stem step by step until the plug stem is un screwed from out of the spring plate 5 6 Remove spring plate and spring un screw lock nut 3 2 Remove valve bonnet 5 from valve body and carefully pull up for version with Fail Close action over the plug stem and for version with Fail Open ac tion together with the plug stem If you want to replace the seat and or the plug for the version with Fail Close action the seat needs to be removed Position the seat wrench Table 1 over the plug stem for version with Fail Close action on the seat so that its recesses are aligned with the seat s spigots Insert the guide part of the seat wrench in the body and unscrew seat with a suitable tool extension Thoroughly clean all parts remove flat gasket 1 1 If the packing leaks unscrew the threaded bushing 5 2 in the valve bon net and remove the individual parts such as V ring packing 4 2 washer 4 3 and spring 4 1 When replacing the plug with a new one the packing rings 4 2 ne
10. ommend horizontal installa tion with the actuator on top to simplify any maintenance procedures when required Note The valve must be installed free of stress I necessary support the piping near the connections Never attach supports to the valve or actuator Thoroughly flush the pipeline prior to installation of the valve so that welding spatter or other impurities carried along by the process medium cannot impair the tight shut off function 2 1 Direction of flow The direction of the medium flow in the valve depends on the process medium and the selected fail safe action For valves with Fail Close action which are used to control gases and vapors the me dium must flow against the valve plug 3 in the closing direction A B For liquid applications the medium must flow into the plug 3 in the opening direc tion B gt For valves with Fail Open action the me dium flows against the plug 3 in the open ing direction A B irrelevant of the pro cess medium type Installation Fail Open R 47 mm Fail Close R 64 mm c 5 7 SSS SS 277 Ni Y rH SY 7 E J az Fail Open Fig 2 Sectional drawings Q Kay LA Fail Close 5 9 1 1 5 5 1 2 3 1 3 1 32 5 3 3 1 2 4 5 2 4 1 4 2 pn 4 4 3 1 1 5 1 4 3 5 2 4 1 5 4 5 1 5 5 5 6 57 5 8 5 9 C9 NOO Fail Open q B
11. or to starting any work on the valve Prior to performing any work on the valve make sure the supply air and control signal are disconnected or blocked to prevent any hazards that could be caused by moving parts EB 8039EN 3 Design and principle of operation 1 Design and principle operation The Type 3351 Pneumatic Control Valve consists of an on off valve and a diaphragm actuator which can be additionally equipped with a handwheel Depending on the whether the control valve is designed for Fail Close action or Fail Open action the control valves can differ in the design of valve seat as well as the ar rangement and design of the valve plug Valve with Fail Close action The spring 5 5 closes the valve when the pressure acting on the actuator diaphragm 5 4 is reduced and upon supply air failure The valve opens when the diaphragm 5 4 is pressurized Valve with Fail Open action The spring 5 5 opens the valve when the pressure acting on the actuator diaphragm 5 4 is reduced and upon supply air failure The valve closes when the diaphragm 5 4 is pressurized For versions with handwheel the handwheel replaces the supply air function In the event of supply air failure the valve can be opened with Fail Close action against the force of the springs 5 5 and it can be closed for valves with Fail Open ac fion 4 EB8039EN 2 Installation Any installation position can be chosen however we rec
12. removed Position the seat wrench Table 1 over the plug stem for version with Fail Close action on the seat so that its recesses are aligned with the seat s spigots Insert the guide part of the seat wrench in the body and unscrew seat with a suitable tool extension Thoroughly cleon all parts remove flat gasket 1 1 If the packing leaks unscrew the threaded bushing 5 2 in the valve bon net and remove the individual parts such as V ring packing 4 2 washer 4 3 and spring 4 1 When replacing the plug with a new one the packing rings 4 2 need to be Maintenance Replacing parts replaced with new ones as well Thoroughly clean all parts as well as the packing chamber 3 4 Reassembling valves in DN 100 1 For version with Fail Close action first place the plug in the body for version with Fail Open action push plug into the valve bonnet 2 Apply sealant order no 8150 0119 to the seat and screw it in using the seat wrench observe tightening torque ac cording to Table 1 3 Packing first insert spring 4 1 and washer 4 3 in the packing chamber then the V ring packing parts 4 2 after applying lubricant order no 8150 0111 to them Loosely screw in threaded bushing 5 2 A Insert flat gasket 1 1 into the body Place the valve bonnet 5 on the body for version with Fail Close action lift the plug stem and carefully guide through the packing Fasten down valve bonnet by tighten
13. ting device 1281 0063 1281 0037 1281 0038 Seot wrench 1281 0040 1281 0041 1281 0042 1281 0043 Wests 1281 0044 1281 0045 1281 0046 1281 0051 1 Fail Close action Tightening torque 150 Nm 400 Nm 850 Nm 1050 Nm Table 2 Tightening torque Nuts 1 2 M10 20 Nm M12 35 Nm M16 90 Nm M20 170 Nm Packing 5 2 M20x1 5 20 Nm M20x1 5 80 Nm M26x1 5 110 Nm M26x1 5 110 N Nuts 5 9 M6 13 Nm M8 18 Nm M8 18 Nm M8 18 Nm 1 On using a torque multiplier with 1 square end 10 8039 EN 4 Description of nameplate SAMSON 3m 4 5 6 7 8 o i O 2 11 13 16 1 CE marking or Art 3 Abs 3 see article 3 3 of PED where applicable 2 Identification no of notified body fluid group and category where applicable 3 Type designation 4 Modification index of valve 5 Material 6 Year of manufacture 7 Nominal size DIN DN ANSI Size 8 Permissible excess operating pressure at room temperature DIN bar ANSI psi 9 Serial number 11 Flow coefficient DIN Kys ANSI 13 Sealing ME Metal STV Solid Stellite ST Stellited NI Nickel plated IN with PTFE stainless steel soft sealing PT with PTFE soft sealing PK with PEEK soft sealing 16 Country of manufacture Fig 4 Valve nameplate Description of nameplate 5 Customer inquiries Please submit the following details Order number Type model number nominal size and version of the valve Pressure and temperature of the process med
Download Pdf Manuals
Related Search